Archive for the ‘Breeze Automotive’ Tag

Type 65 Coupe Update: Foot Boxes, Firewall, Gas Pedal   Leave a comment

It’s been a few weeks since I posted an update. Some people have been asking for some news, so here we go. . .

I am preparing the chassis so I can install the engine and transmission. This means that I have to finish the firewall, which means prepping and painting the foot boxes and routing and mounting the brake and fuel lines.

I decided to finish the engine bay with silver Rust-Oleum high temperature BBQ paint. This is a change from my thoughts on powder coating and appliance epoxy. . . The appliance epoxy has an upper temperature limit of 200 degrees F, and I think engine bay heat is higher than an oven. The BBQ paint is good for 1200 degrees F or something like that. Depending on how the engine bay looks, I may strip everything off and re-finish with powder coat later. But for now, the silver BBQ paint looks OK. The nice weather last week allowed me to do some rattle-can spraying outside.

I permanently mounted my first aluminum panel – the driver’s side foot box front. I am using Permatex Ultra Black number 2105 silicone adhesive. This is what Kirkham Motors uses for their builds, so I will use what they use. It can be used as an adhesive as well as a gasket, so this extends its usefulness around the shop.

References: Kirkham online build  and Permatex Ultra Black goop

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Above right is a close-up of the BBQ paint finish on one of the pedal box panels. Looks OK. There is a slight texture to the finish. The color is actually silver, the blue-ish tint is probably from sunlight diffracting from somewhere.

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Above left, a “dry fit” of the driver side foot box front panel. You can see the cookie sheet heat shields in place. Above right, using the panel as a pattern to cut the insulation mat – just place the panel onto the backing side of the mat, press down and then cut with shears or a knife. Final trimming is done with a utility knife.

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Cool-It heat and sound insulation is applied to the interior side of the foot box panel. The “bubbles” you see are from the riv-nuts and screws poking out from the other side. On the right, I wanted to make sure the adhesive stuck properly at the top of the panel, so I used some clamps to squeeze evenly. My good friend Norm Abram always says, “You can never have too many clamps.”

The Accelerator Cable and Pedal

I mounted the accelerator cable as well as the Russ Thompson gas pedal, sold by Breeze Automotive. The instructions are different from what is being supplied by Factory Five Racing now. (I am getting used to this. . . )

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The picture above shows some of the gas pedal mounting parts that come with the Complete Kit. The Thompson / Breeze pedal instructions say something about a “green plastic barbed clip” at the end of the throttle cable. This green thing is no longer what comes with the kit. Instead, there is a little square “plug” that is too big to fit into the pedal mount.

Rather than cutting off the ball-end at the throttle cable or drill a bigger hole in the mount, I decided to carefully cut some of the plastic from the center barb so it would fit snugly into the mounting hole – not much has to be shaved off, it is something like a sixteenth of an inch or so. Then I made a slit in the square plastic thing as shown so the cable could slip in with the ball intact.

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As you can see above, I added a fender washer (painted black) to the throttle cable mounting point, this is just for looks.

This is Irritating

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For some reason, this bothered me today, but then I realized not many tubes of caulk gun goop come with caps.  Anyway, I used a pen cap to close the tube. I hope this works, I only needed a few beads for this build session.

Some Great Looking Door Panels on Order!

I ordered a set of leather door panels from Levy Racing earlier this week. They look like this:

Levy Racing Coupe Door Panels

Type 65 Coupe Update Plus a New Antenna   Leave a comment

Some Body Parts, More IRS Conundrum and a New Microwave Antenna for KH6WZ

Inspired by a post on the Factory Five Racing forum and the dry and sunny weather this weekend, I decided to paint some of my body mounting parts. I am using gloss black Rust-Oleum Appliance Epoxy paint for these pieces. I have used this paint for my electronic and radio projects with good results. The paint dries very hard and is waterproof and washable, perfect for these parts.

Surface prep is easy for this paint, I scuff the surface with a 60 grit sanding disc on my random orbit sander. For the hard to reach nooks and crannies, I use a wire wheel chucked in my hand drill. Then I use liquid dish soap and water to wash off the grit and any oils. No primer is needed for this paint. Then I apply two or three light fog coats first, and then blast a thick coat for the fourth or fifth and final coat.

Here is a “before” and “after” picture of the front nose mounting hinge.

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I did the same with the door hinges. Here you can see some weld splatter that will interfere with the mounting bolts, so I used a Dremel tool to grind those weld balls off.

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Although many of these parts will not be seen, I do not want them to rust. Other parts will be painted in the same way, and include the door frames, the rear glass hatch hardware and the emergency brake mechanism.

Meanwhile . . .

After spending some time fiddling with the factory-supplied accelerator pedal, I decided to buy an aftermarket gas pedal instead. I ordered one of Russ Thompson’s gas pedals earlier this week from Breeze Automotive, one of the Factory Five Racing Forum supporters. I was amazed the box arrived on Thursday – that was fast!

The new gas pedal is really a machined aluminum sculpture. Pictures on this will be coming later, since I need to get the engine mounted before the gas pedal goes in.

IRS – Finished – Sort Of . . .

The IRS section is now fully “dry-fit” completed, and the bolts will be tightened to specs in the next work session. One thing that is putting this assembly step on hold are the mounting points for the lower control arms – see the gold color on the right of this picture? That is the mounting bolt and as you can see, there is a lot of empty space between the mounting ear and the thin washer (the manual calls them shims). This cannot be correct, and I need to find what is wrong here. . . .

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Just after I ordered my Type 65 Coupe kit, I came across a lot of posts on the forums about the IRS  shafts (CV joints) coming apart. Those messages made me worry, but when my kit was shipped, the CV axles were on back-order. I called Factory Five Racing technical support, and they assured me that the problem has been fixed.

I am happy to report that my IRS system assembly went very smoothly, after the pumpkin was in place. The CV axles slipped right into the differential, and it felt just like many posts said – you can feel it lock into place. No hammering, no drama and no R- and X-rated words necessary.

Once again, Chris comes to the rescue by posting images of the IRS knuckles and which part goes on the left side and which one goes on the right side.

Here are some additional pictures of the IRS components and system . . . . “R” is for Right side of vehicle (passenger side in the US)

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Above left: The IRS upper control arm has another pair of small mounting tabs that are not mentioned in the assembly manual. No pictures are included in the manual, either. After a quick search on the Factory Five forum, I found out the smaller set of tabs point downward, and are used for quad shocks – used to minimize wheel hop during acceleration.

Give Me a Brake – Again

Now, the rear brakes are another story. Seems the Factory sent me the wrong rear brake kit. So now I have to wait for the correct parts to arrive, and then have to send the wrong parts back. . . Stay tuned for more . . .

Another Box Arrived this Week – a 10 GHz Slot Antenna

I received this nicely machined antenna for 10 GHz earlier this week. It is made by fellow SBMS member Dan, W6DFW.

Here’s a picture of this omni-directional microwave antenna. The background is the radiation pattern plotted by another SBMS member, Chuck, WA6EXV.

I am planning on using this to make my roving 10 GHz station even more portable, perhaps getting on 10 GHz FM mobile. More on this item and possible applications at station KH6WZ later.

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